System and method for providing a reflective insulation layer

ABSTRACT

A reflective insulation layer is provided for a structure. The structure includes a wall and spaced-apart strips which extend along the wall from a top portion of the wall to a bottom portion of the wall. The reflective insulation layer includes a low emittance layer having first perforations, and a synthetic polymer layer having second perforations. Additionally, the reflective insulation layer includes an expander spaced between the low emittance layer and the synthetic polymer layer. The expander couples the low emittance layer to the synthetic polymer layer to form a first air space between the low emittance layer and the synthetic polymer layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/080,719, filed Jul. 15, 2008, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to insulation layers, and more particularly, to a system and method for providing reflective insulation layers.

Thermal insulation is an important characteristic of most residential, commercial, agricultural, and industrial building structures, including residences. Conventional thermal insulation systems include reflective insulation technology, which attempts to reflect heat energy back to the atmosphere and/or not emit heat energy into a structure during the summer. Additionally, this conventional reflective insulation technology attempts to reflect heat energy back into the structure and/or not emit heat energy into the atmosphere during the winter. For example, the assignee of the present application designed a reflective insulation layer including a metallic foil layer, a paper layer, and a paper expander integral with the paper layer, which couples the metallic foil layer and the paper layer.

However, conventional reflective insulation systems have several shortcomings. For example, conventional reflective insulation systems include cellulose, a material which, in the presence of moisture, can facilitate the growth of mold. Additionally, the layers of conventional reflective insulation systems do not structurally accommodate vapor transmission, without perforations through all the layers.

Accordingly, it would be advantageous to provide a system for providing a reflective insulation system which does not facilitate the growth of mold and further provides vapor transmission to all of the layers of the reflective insulation system.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment of the present invention, a reflective insulation layer is provided for a structure. The structure includes a wall and spaced-apart strips which extend along the wall from a top portion of the wall to a bottom portion of the wall. The reflective insulation layer includes a low emittance layer having first perforations, and a synthetic polymer layer having second perforations. Additionally, the reflective insulation layer includes an expander spaced between the low emittance layer and the synthetic polymer layer. The expander couples the low emittance layer to the synthetic polymer layer to form a first air space between the low emittance layer and the synthetic polymer layer.

In another embodiment of the present invention, a reflective insulation layer is provided for a structure. The structure includes a wall and spaced-apart strips which extend along the wall from a top portion of the wall to a bottom portion of the wall. The reflective insulation layer includes a low emittance layer, an intermediate low emittance layer, and an outer synthetic polymer layer. A first expander is spaced between the low emittance layer and the intermediate low emittance layer, to form a first air space between the low emittance layer and the intermediate low emittance layer. Additionally, a second expander is spaced between the intermediate low emittance layer and the outer synthetic polymer layer, to form a second air space between the intermediate low emittance layer and the outer synthetic polymer layer.

In another embodiment of the present invention, a method is provided for providing reflective insulation for a structure. The structure has a wall and spaced-apart strips extending along the wall from a top portion of the wall to a bottom portion of the wall. The method includes forming a reflective insulation layer. The step of forming the reflective insulation layer includes forming a first plurality of perforations in a low emittance layer, and forming a second plurality of perforations in a synthetic polymer layer. Additionally, the step of forming the reflective insulation layer includes spacing an expander between the low emittance layer and the synthetic polymer layer, where the expander couples the low emittance layer to the synthetic polymer layer, to form a first air space between the low emittance layer and the synthetic polymer layer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a plan view of an exemplary embodiment of a system for providing a reflective insulation layer according to the present invention;

FIG. 2 is a top view of an exemplary embodiment of the system for providing a reflective insulation layer illustrated in FIG. 1;

FIG. 3 is a top view of an exemplary embodiment of a system for providing a reflective insulation layer according to the present invention;

FIG. 4 is a flow chart illustrating an exemplary embodiment of a method for providing a reflective insulation layer according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

In describing particular features of different embodiments of the present invention, number references will be utilized in relation to the figures accompanying the specification. Similar or identical number references in different figures may be utilized to indicate similar or identical components among different embodiments of the present invention.

FIG. 1 illustrates a reflective insulation layer 10 for a structure 12. The structure 12 includes a wall 14 with a plurality of horizontally spaced-apart strips (or vertically oriented) 16,18 and vertically spaced apart strips (or horizontally oriented) 20,22. The horizontally spaced-apart strips 16,18 extend along the wall 14 from a top portion 24 of the wall 14 to a bottom portion 26 of the wall 14. In an exemplary embodiment, the horizontally spaced-apart strips 16,18 and/or vertically spaced-apart strips may be spaced by 16″ or 24″, as appreciated by one of skill in the art. Although FIG. 1 illustrates that the wall 14 includes the horizontally spaced-apart strips 16,18 and the vertically spaced-apart strips 20,22, in the embodiments of the present invention, the wall need not be formed with horizontally spaced-apart strips and vertically spaced-apart strips, and may be formed from either the horizontally spaced-apart strips or the vertically spaced-apart strips, with any spacing. Additionally, although FIG. 1 illustrates that the horizontally spaced-apart strips 16,18 extend from the top portion 24 to the bottom portion 26 of the wall 14, the horizontally spaced apart strips need not extend the entire length of the wall.

FIG. 2 illustrates the reflective insulation layer 10 upon installation to the wall 14 of the structure 12. Although the exemplary embodiment of FIG. 2 illustrates a block wall, the reflective insulation layer 10 may be similarly installed on a frame wall, for example, as appreciated by one of skill in the art. The reflective insulation layer 10 includes a low emittance layer 28, which tends to reflect radiation energy and/or not emit radiation energy, for example, having a plurality of first perforations 30, and a synthetic polymer layer 32 having a plurality of second perforations 34. Although the low emittance layer 28 may be formed from aluminum foil, the low emittance layer 28 may be formed from any metalized material. In an exemplary embodiment, the first perforations 30 may have a spatial density of approximately ⅜″ or 0.04 inches square pattern or a pattern and size that would produce a perm rating of at least 5 per ASTM E96, water vapor permeance standard, as appreciated by one of skill in the art. In another exemplary embodiment, the second perforations 34 may have a spatial density of ⅜″ or 0.04 inches square pattern or a pattern and size that would produce a perm rating of at least 5 per ASTM E96, water vapor permeance standard, as appreciated by one of skill in the art. However, one or both of the perforations 30,34 may have a spatial density of any square pattern, linear pattern, or a random pattern, for example.

Additionally, the reflective insulation layer 10 includes an expander 36 which is spaced between the low emittance layer 28 and the synthetic polymer layer 32, and is configured to couple the low emittance layer 28 to the synthetic polymer layer 32 to form a first reflective air space 38 between the low emittance layer 28 and the synthetic polymer layer 32. The expander 36 is coupled to respective inner surfaces 40,42 of the low emittance layer 28 and the synthetic polymer layer 32. Although FIG. 2 illustrates that the expander 36 is positioned between the inner surfaces 40,42 toward the ends of the layers 28,32 and adjacent the horizontally spaced-apart strips 16,18, the expander may be positioned at any location between the layers 28,32, provided that it couples the inner surfaces 40,42 together. In an exemplary embodiment, the expander 36 is formed from a synthetic, non-paper material.

The first perforations 30 in the low emittance layer 28 and the second perforations 34 in the synthetic polymer layer 32 are configured to permit vapor transmission through the respective low emittance layer 28 and synthetic polymer layer 32. The synthetic polymer layer 32 is formed from a mold-resistant material, such as a material excluding cellulose to enhance a resistance to of the growth of mold. In an exemplary embodiment of the present invention, a reflective insulation layer 10 may achieve one or more of the following performance characteristics: no growth of mold & mildew in accordance with ASTM C1338, an approximate 7.46 water vapor permeance in accordance with ASTM E96, an approximate <25 flame spread rating, an approximate <50 smoke developed rating, a class A interior wall and ceiling finish classification in accordance with ASTM E84; no corrosivity, no bleeding, and no delamination, in accordance with ASTM D3310; and an approximate 0.034 foil emittance in accordance with ASTM C1371, for example. The numeric performance characteristics listed above are merely exemplary, and the synthetic polymer layer of the present invention may be formed from a mold-resistant material which deviates from these numeric performance characteristics, yet still achieves an acceptable level of mold resistance.

As illustrated in FIG. 1, the reflective insulation layer 10 has a width 33 dimensioned with the plurality of horizontally spaced apart strips 16,18 or vertically spaced apart strips 20,22, depending on the orientation of the reflective insulation layer 10. For example, the reflective insulation layer 10 secured to horizontally spaced apart strips 16,18 is rotated 90 degrees from the reflective insulation layer 10 secured to vertically spaced apart strips 20,22. As previously discussed, although the wall 14 of FIG. 1 has both horizontally spaced-apart strips 16,18 and vertically spaced-apart strips 20,22, the wall may have either horizontally spaced apart strips or vertically spaced-apart strips, and thus the reflective insulation layer would be oriented in the manner described herein, based on the individual configuration of the strips of each particular wall. The width 33 of the reflective insulation layer 10 is dimensioned with the plurality of spaced apart strips 16,18 such that an opposing first and second side 44,46 of the respective reflective insulation layer 10 is secured along a respective first and second strip 16,18, where the first and second strips 16,18 are consecutively spaced apart along the wall. Upon securing the respective reflective insulation layer 10 to the first and second strips 16,18, the expander 36 is configured to form the first reflective air space 38 and a second reflective air space 52 (FIG. 2) between the wall 14 and the low emittance layer 28. The first and second reflective air spaces 38,52 are configured to restrict air movement within a cavity 53 defined by the first strip 16, the second strip 18, the reflective insulation layer 10 and the wall 14, where the restriction of air movement within the cavity 53 reduces a passage of heat flow by convection through the cavity 53. The low emittance layer 28 is configured to reflect or not emit radiation from passing into the cavity 53 to reduce a passage of heat flow by radiation through the cavity. In an exemplary embodiment, an R value (a unit of measurement of thermal resistance) of the reflective insulation layer is a value between 4.1 and 5.1, based on the thickness of the strips 16,18. As with the previously discussed numerical performance characteristics, the reflective insulation layer may have an R value which deviates from the numerical value listed above, and still effectively reduces a passage of heat flow through the cavity.

In securing the first and second side 44,46 of the reflective insulation layer 10 to the respective first and second strip 16,18, the reflective insulation layer 10 is oriented with the synthetic polymer layer 32 facing an opposite direction to the wall 14 and the low emittance layer 28 facing the wall 14. The first side 44 is attached along the first strip 16 from the top portion 24 to the bottom portion 26 of the wall 14. The reflective insulation layer 10 is severed across the width 33 adjacent to the bottom portion 26 of the wall 14. The reflective insulation layer 10 is stretched across the width 33 between the first and second strip 16,18, upon which the second side 46 is attached along the second strip 18 from the top portion 24 to the bottom portion 26. Additionally, a top end 54 and a bottom end 56 of the reflective insulation layer 10 opposite to the top end of the reflective insulation layer are respectively attached, such as with staples, screws, or an adhesive, to a top strip and a bottom strip, the top strip and bottom strips are configured to intersect the spaced apart strips respectively adjacent to the top portion and the bottom portion of the wall.

FIG. 3 illustrates an additional embodiment of a reflective insulation layer 10′ including a low emittance layer 28′, such as an aluminum foil or metalized material, including a metalized polymer, for example; an intermediate low emittance layer 29′ such as an aluminum foil or material with metallic deposits; and an outer synthetic polymer layer 32′. In an exemplary embodiment of the present invention, the outer synthetic polymer layer 32′ may have one or more of the following performance characteristics: an approximate weight of 81±10% GSM using the ASTM D 3776-96 method, an approximate M.D. tensile strength of 250±20% N/2.5 cm using the ASTM D 5034-90 method, an approximate C.D. tensile strength of 205±20% N/2.5 cm using the ASTM D 5034-90 method, an M.D. elongation of 90±20% using the ASTM D 5034-90 method, and a C.D. elongation of 95±20% using the ASTM D 5034-90 method. As with the previously discussed numerical performance characteristics, the outer layer of the additional embodiment illustrated in FIG. 3 may have a performance characteristic which deviates from the numerical performance characteristics listed above.

The reflective insulation layer 10′ includes a first expander 36′ spaced between the low emittance layer 28′ and the intermediate low emittance layer 29′ to form a first reflective air space 38′ between the low emittance layer 28′ and the intermediate low emittance layer 29′. In an exemplary embodiment of the present invention, the first expander 36′ with a 48 gauge (0.00001″ units) may have one or more of the following performance characteristics: an approximate nominal yield of 41,200 in²/lb, approximate MD and TD F-5 respective values of 15,900 lb/in², and 14,600 lb/in², approximate MD and TD tensile strengths at break of 39,800 lb/in² and 36,300 lb/in², approximate MD and TD elongation at break values of 120% and 129%, approximate MD and TD heat shrinkage at 190° C. of 3.7% and 0.4%, approximate A-side and B-side coefficient of friction values of 0.40 and 0.30 and an approximate haze value of 2.1%. As with the previously discussed numerical performance characteristics, the first expander 36′ may have a performance characteristic which deviates from the numerical performance characteristics listed above.

Additionally, the reflective insulation layer 10′ includes a second expander 37′ between the intermediate low emittance layer 29′ and the outer synthetic polymer layer 32′ to form a second reflective air space 53′ between the intermediate low emittance layer 29′ and the outer synthetic polymer layer 32′. Upon securing the respective reflective insulation layer 10′ to the first and second strips 16′,18′, the first expander 36′ forms the first reflective air space 38′ and a third reflective air space 52′ between the wall 14′ and the low emittance layer 28′. Additionally, the second expander 37′ forms the second reflective air space 53′ upon securing the reflective insulation layer 10′ to the first and second strips 16′,18′. In an exemplary embodiment of the present invention, a reflective insulation layer 10′ may achieve one or more of the following performance characteristics: no growth of mold & mildew in accordance with ASTM C1338, an approximate 7.46 water vapor permeance in accordance with ASTM E96, an approximate <25 flame spread rating, an approximate <50 smoke developed rating, a class A interior wall and ceiling finish classification in accordance with ASTM E84; no corrosivity, no bleeding, and no delamination, in accordance with ASTM D3310; and an approximate 0.034 foil emittance in accordance with ASTM C1371, for example. Those elements of FIG. 3 not discussed herein, are similar to those elements discussed above, without prime notation, and require no further discussion herein. As with the previously discussed numerical performance characteristics, the reflective insulation layer 10′ may have a performance characteristic which deviates from the numerical performance characteristics listed above. Additionally, in an exemplary embodiment, the first and second expanders 36′, 37′ may be formed from a synthetic, non-paper material.

FIG. 4 illustrates an exemplary embodiment of a method 100 for providing reflective insulation for a structure 12. The method 100 begins at block 101, by forming 102 a reflective insulation layer 10. The forming 102 step includes forming 104 a first plurality of perforations 30 in a low emittance layer 28, and forming 106 a second plurality of perforations 34 in a synthetic polymer layer 32. Additionally, forming 102 the reflective insulation layer 10 includes spacing 108 an expander 36 between the low emittance layer 28 and the synthetic polymer layer 32, where the expander 36 couples the low emittance layer 28 to the synthetic polymer layer 32 to form a first reflective air space 38 between the low emittance layer 28 and the synthetic polymer layer 32. In an alternate method, a plurality of perforations may be formed in an additional low emittance layer, and the additional low emittance layer may be spaced from the low emittance layer with an additional expander.

This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to make and use the embodiments of the invention. The patentable scope of the embodiments of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

1. A reflective insulation layer for a structure, said structure having a wall and a plurality of spaced-apart strips extending along said wall from a top portion of the wall to a bottom portion of the wall, said reflective insulation layer comprising: a low emittance layer having a plurality of first perforations; a synthetic polymer layer having a plurality of second perforations; an expander spaced between the low emittance layer and the synthetic polymer layer, said expander configured to couple said low emittance layer to said synthetic polymer layer to form a first air space between said low emittance layer and said synthetic polymer layer.
 2. The reflective insulation layer of claim 1, wherein the first perforations in the low emittance layer and the second perforations in the synthetic polymer layer are configured to permit vapor transmission through the respective low emittance layer and synthetic polymer layer.
 3. The reflective insulation layer of claim 1, wherein said expander is coupled to a respective inner surface of said low emittance layer and said synthetic polymer layer.
 4. The reflective insulation layer of claim 3, wherein said synthetic polymer layer is comprised of a mold-resistant material.
 5. The reflective insulation layer of claim 4, wherein said mold-resistant material excludes cellulose to enhance resistance to a growth of mold, said low emittance layer being an aluminum foil layer.
 6. The reflective insulation layer of claim 1, wherein said reflective insulation layer has a width dimensioned with said plurality of spaced apart strips such that an opposing first and second side of said respective reflective insulation layer are secured along a respective first and second strip, said first and second strips being consecutively spaced apart along said wall.
 7. The reflective insulation layer of claim 6, wherein upon securing said respective reflective insulation layer to said first and second strips, said expander is configured to form said first air space and a second air space between said wall and said low emittance layer.
 8. The reflective insulation layer of claim 7, wherein said first and second air space are configured to restrict air movement within a cavity defined by said first strip, second strip, reflective insulation layer and said wall, said restriction of air movement within said cavity being provided to reduce a passage of heat flow by convection through said cavity.
 9. The reflective insulation layer of claim 8, wherein said low emittance layer is configured to reflect radiation from passing into said cavity to reduce a passage of heat flow by radiation through said cavity.
 10. The reflective insulation layer of claim 6, wherein an R value of the reflective insulation layer is a value between 4.1 and 5.1.
 11. The reflective insulation layer of claim 6, wherein upon securing said first and second side to said respective first and second strip: said reflective insulation layer is oriented with said synthetic polymer layer facing an opposite direction to the wall and said low emittance layer facing the wall; said first side is attached along said first strip from said top portion to said bottom portion of the wall; said reflective insulation layer is severed across said width adjacent to the bottom portion of the wall; and said reflective insulation layer is stretched across the width between said first and second strip, and said second side is attached along said second strip from said top portion to said bottom portion.
 12. The reflective insulation layer of claim 11, wherein upon securing said first and second side to said respective first and second strip: a top end and bottom end opposite to said top end of said reflective insulation layer are respectively attached to a top strip and a bottom strip, said top strip and bottom strips are configured to intersect said spaced apart strips respectively adjacent to said top portion and said bottom portion of said wall.
 13. A reflective insulation layer for a structure, said structure having a wall and a plurality of spaced-apart strips extending along said wall from a top portion of the wall to a bottom portion of the wall, said reflective insulation layer comprising: a low emittance layer; an intermediate low emittance layer; an outer synthetic polymer layer; a first expander spaced between said low emittance layer and said intermediate low emittance layer to form a first air space between said low emittance layer and said intermediate low emittance layer; and a second expander spaced between said intermediate low emittance layer and said outer synthetic polymer layer to form a second air space between said intermediate low emittance layer and said outer synthetic polymer layer.
 14. The reflective insulation layer of claim 13, wherein upon securing said respective reflective insulation layer to said strips, said first expander is configured to form said first air space and a third air space between said wall and said low emittance layer, said second expander being configured to form said third air space
 15. A method for providing reflective insulation for a structure, said structure having a wall and a plurality of spaced-apart strips extending along said wall from a top portion of the wall to a bottom portion of the wall, said method comprising: forming a reflective insulation layer, comprising; forming a first plurality of perforations in a low emittance layer, forming a second plurality of perforations in a synthetic polymer layer, and spacing an expander between the low emittance layer and the synthetic polymer layer, said expander configured to couple said low emittance layer to said synthetic polymer layer to form a first air space between said low emittance layer and said synthetic polymer layer.
 16. The method of claim 15, further comprising: installing said reflective insulation layer including a first side and a second side opposite to the first side along said wall, said spaced-apart strips including a first and second strip being consecutively spaced apart along said wall, said installing comprising: orienting said synthetic polymer layer to face an opposite direction to the wall, and orienting said low emittance layer to face the wall; attaching said first side of said reflective insulation layer along said first strip from said top portion to said bottom portion of the wall; severing said reflective insulation layer across a width of said reflective insulation layer adjacent to said bottom portion of the wall; stretching said reflective insulation layer across said width from the first strip to the second strip; and attaching said second side of said reflective insulation layer along said second strip from said top portion to said bottom portion of the wall
 17. The method of claim 16, wherein said reflective insulation layer further includes a top end and a bottom end opposite to the top end, said installing further comprising: attaching said top end and bottom end of said reflective insulation layer along a respective top strip and bottom strip, said top strip and bottom strip intersecting said spaced apart strips respectively adjacent to said top portion and said bottom portion of said wall. 